Audio Innovations PG/Fi cut -through. 4x15's, 18K rms, 158@38Hz

[Ryan Autry]

Headunit:
Mac Mini, digital out
17" touchscreen in dash.


Amplification:
(4) Phoenix Gold Elite.1 ( 4,500w x 1 @ 1ohm, clamped w/AMM-1 ) (1 amp for each Fi SP4)
(2) Phoenix Gold Elite.4 ( 150w x 4 @ 4ohm )


Sound Processing:
(1) Audison BitOne, digital in


Front/Rear stage:
(4) Phoenix Gold Elite 6.5 component sets in-cab.
(4) Phoenix Gold Elite 6.5 component sets in-rear tailgate.


Subwoofers:
(4) 15" Fi SP4 w/cooling, spaced spider


Enclosure:
11.0cu^ft after displacement. 6th order, tuned @ 36.0Hz.


Interconnects:
Stinger & custom made AI RCA's.

Wiring:
(4) runs of 4/0 from alts to batteries for power
(2) runs of 4/0 from alt bracket to batteries for ground
(4) 2/0 frame grounds in rear
(4) 2/0 frame grounds in front


Charging:
( Shuriken BT-120 battiers (960 aH total)
(4) MechMan 320amp Alternators, powdercoated charcoal
MechMan Adjustable Voltage Boost Module set @ 14.9v
CUstom Toolmaker Buss bars for batteries
CUstom Toolmaker 4/0 fuse block
Custom Toolmaker 4/0 to 1/0 reducers for the amplifiers


Misc.
150+ Sq^ft of Stinger Roadkill Expert Series sound deading material



This build was a team effort. I'd like to thank the entire AI crew for all their dedication and hard work. I'd like to personaly thank Phoenix Gold, Stinger, Anthony (Toolmaker), and last but not least, Fi for their support with this build.

Technicians responsible for this...

Ryan, enclosure & overall design of build.
Shawn, enclosure fabrication.
Matt/James/Ryan/Ray, upholstery.
Matt/James/Ryan, amp rack fab
Matt/James/Ryan, wiring.
Matt/James, mids/highs.
Matt, battery rack
David, TV in dash
David, wire tuck in engine





Well, it all started here. April 2003. Yes, this build log is over 10 years long...



The first deck, a Clarion 845 w/Audio Control Three.1


Enclosure build. The details in this enclosure was to ensure a long life. All the panels were

designed to be removed over and over just in-case of sub failure.







It was easier to build the enclosure with the bed off the truck.



We cut the bed with a plasma to make room for the new air pump/tank setup.





Start of the front panel in the interior




Here is a brace we made for the window that didn't make it into the final build. We dubbed it

the whale penis.

[Ryan Autry]

panel made for the LED lights







We welded 1x1" square tubing around the cut to strengthen the back wall.



By now you can really see the enclosure taking form.











our original 13.3" LCD in the dash.



We wanted to clean up the engine bay. So we did a little wire tuck. relocated the fuse block

and ecu into the cab.


Dash out. Here you can see the ECU and block no inside.



Engine bay before.


Engine bay after.

[Ryan Autry]

This amp setup was interesting. We ended up throwing 7 batteries, 8 Massive DB8000 amplifier and 4 Ascendant Audio Mayhem woofers into the truck. Sure, it was a mess, but damn loud.

We took the back plate off the amplifiers and made them out of 1/4" MDF while adding a 100mm fan to each amplifier forcing cool are across the boards.





We decided to try an wiring these amplifier down to .17 each. We had two amplifiers for each woofer. So, a minimum of 8,000rms to each woofer. We tested one woofer only and as you can see from the screen, 153.4@38Hz with only one woofer. Yes, a 153.4@38HZ!!!! But, it didn't work.

the woofer did not like 8k rms @ 38hz. It launched the cone into the front seat.

We had to wire the amplifiers up and replace that cone. We clamped roughly 4,000rms per woofer. This was more manageable for our 2,500rms woofers.






I'm sure you all what to know what it did on the meter at this point?

This is a term-lab score in the MECA legal headrest position @ 30hz.


This is a term-lab score in the MECA legal headrest position @ 38hz. 158.0 was a huge number for our truck. We didn't think it would do such a number off 16,000rms. But it did.

Uh oh, those aren't Mayhems?? So, new woofers? Why? Because the Mayhem's couldn't take the 4k rms on a daily basis like we thought they would. We had two woofers catch fire after long demo's. So we replaced the woofer with some old RE SX 15's we had in the back room. Since we just got out Elite amplifiers in, we thought it would be a perfect match off the 6,400rms that the Elite.1's are rated at.

This was a Glorious day. We were extremely excited to have these amplifiers in our possession.

[Ryan Autry]

Started building the amp rack design that we're currently using. This is housing the two

Elite.1's and Elite.4's. We never planned on adding more power than this. So we finalized the

amp rack.





So, what did it do off one single Elite.1 and (4) SX 15's?

153.7 @ 34Hz at the Headrest (MECA)



152.1 @ 30Hz at the Headrest (MECA)


150.1 @ 25Hz at the Headrest (MECA)



We tidied up the wiring under the Elite amp rack, since this was going to be our FINAL

build in this truck.







Here is the final amp covering.

[Ryan Autry]

What's this? New woofers again? Yup! The SX's didn't like both Elite.1's. They all burned... all of them.
So after finding out these Elite amplifiers put out close to 6,000watts, clipped. We had to get a woofer that could handle 3,000 on a daily basis? So we picked Fi SP4's. We love the

large 10" spaced spiders and 4" coils.





So, how loud is it on the two Elite.1's and (4) SP4's?

156.8@38Hz at the headrest (MECA)

Sure, we're down from 158 with the 8 massives and mayhem woofers. But I'm confident we could play it all day long.

Some clamp results of the Elite.1's. 4,300rms unclipped @ 1.15ohm @ only 10.6v :0

Here we started changing the interior from Tan to Dark Grey. We installed black carpet and charcoal suede on the headliner.

Started wrapping interior panels.


Center Console is in and getting wrapped.



The dash was a challenge, but went well. Ray killed it here.






Here are a couple pictures of our truck at a recent show. This truck draws a huge crowd.


The expression on this girl tells it all.

[Ryan Autry]

Our newest build for 2013... wait, WHAT!? A new build? I know, I said the above build was our "final" build. But it only lasted about 10 months until we wanted more. These woofers seem to be handling the 2,300ish rms great. But we're always curious what would happen if we doubled the power? Well, it's time to find out.

Here is the 4/0 wire we bought in comparison to Stingers HPM 1/0, 4ga, and 8ga.


Here are the 4 Alts and the six runs of 4/0 wire. Our goal was to keep the wiring as tucked

and cleanly ran as possible. All the wire is wrapped in Techflex and then heat shrinked.








Toolmaker 4/0 - 1/0 reducers for our Elite.1's
We noticed the Elite's are power hungry. Pulling close to 460A of current. From what we all

know, 1/0 won't carry 450A of current efficiently. So we decided 4/0 was in-order. Of course we need a fuse block that can house 4/0. Thanks again to Toolmaker for this work of

art.






So, we start again. The easiest way to start a new amp rack and build is start with a clean

slate.



While we were cleaning up the wiring. We completely rewired the air bag wiring in techflex and

heatshrink.



Battery Rack all welded up.


Buss bars installed.




Found a nice spot for the fuse block.




6 Elite Amplifiers.

[Ryan Autry]

new amp rack base.


The most recent amp rack. Notice the fans? We have to keep the Elites cool under long demos.


Wiring up the four Elite.1's on the top amp rack. All the wiring techflexed and shrinked.





July 4th I was at my brothers pool party thinking about our newest build. The only thing I didn't like about it was the amp base. When we made it last year, it was functional. But not built to our standards. So I drew what I would like to build when we get back to the shop.


Out with the old. I knew we could stream line this base. But I wanted to make the push/pull

cooling system more efficient.




started with two pieces of 3/4" MDF.


Laying out the cut lines.


cutting.



Notice the relief for the air flow?


Bottom board with the Fans. We rounded over the wood for better flow.

[Ryan Autry]

Here is the relief channel for the air flow.









Fans all wired up and wires wrapped in techflex.



New amp rack wrapped in vinyl.


Custom made RCA's


We re-wrapped the top amp cover in Vinyl. Please just say no to suede.


The 4 elites on the top amp rack. We added LED on the underside so you could see the work under the amps.



This is one of my favorite parts of this current build. We use Speakon connectors for all our signal, remote, bass know, remote voltage, fan power/ground, LED lighting etc. When we need to take the amp rack off, it's very modular. Just unplug the speakons, remove power/ground and it's off.We can have all the amps uninstalled in under 5 mins.

mmm, 4/0! Lots of it.


Underneath the top amp rack.


THAT'S WHERE THAT ALLEN WRENCH WENT!

[Ryan Autry]

Subwoofer speaker wire. All Stinger 8ga.



4/0 reducers made by Toolmaker.


Remote, RMD, and Bass Knob wiring behind the amps.



Our custom made RCA's.




Here you can see the Allen Bolts at the back of the amp rack. This is where we terminate the

sub wires. Either wired down to .17ohm per amp or wired up @ .70ohm per amp.



here we start the Elite.4 install on the rear.


wrapped.



We keep the truck plugged in every night with a 100a power supply. It keep the batteries @ 13.0v

Here we sit today. I'll keep this thread updated.



This is where all the Magic happens. Our install bay. Our fabrication room is to the right.




Here are a few pictures of our Fabrication Room.

Here you can see we have enough room to pull a car in if needed.

Our tablesaw

Our routering station. (4) 1.75HP Porter-Cable in JessEm lifts w/an assortment of Mobile Solutions Templates.

[Ryan Autry]

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